Kyle Hummel

Induction is a curious member in the family of heat treating. Its presence is valuable, yet there’s a mystery surrounding it that has even veteran heat treaters exploring it to gain understanding. Journey through this induction hardening primer to learn about this important misfit of the heat treating world.

This Heat Treat Today Technical Tuesday original content feature, written by Kyle Hummel, P.E., COO at Contour Hardening, first appeared in Heat Treat Today's May 2021 Induction print edition. Feel free to contact Karen Gantzer at karen@heattreattoday.com if you have a question, comment, or any editorial contribution you’d like to submit.

In the world of heat treat, induction hardening just doesn’t fit in. There is no big furnace, cycle times are a matter seconds, and the entire process takes place right before your eyes rather than behind the walls of a furnace chamber. Many heat treaters have one old induction machine sitting in the corner of the shop floor, with one remaining employee who knows how to operate it.

Induction is different than all other types of heat treatment, and even many metallurgists shy away from the "black magic" that occurs during the process. When I ask customers how familiar they are with induction hardening, they usually state that they have seen it before, mention something about a coil, but that’s about the extent of their knowledge.

The purpose of this article is to give readers, who are not familiar with the induction hardening process, some background on the fundamental aspects and terminology of the process. The information encompasses the most common questions I am asked by new customers as well as information I would provide in training new employees. My hope is that it will give you enough familiarity with the process to become more comfortable engaging in a conversation about induction hardening.

Why Use Induction?

Selective hardening – Induction allows you to harden only the desired portion of a part, whereas most furnace-based heat treat processes treat the entire component. This means you can harden the particular area that you want to harden, while leaving the rest of the component soft enough to machine further.

Strength – Not only does the part become harder, but the stress (called residual compressive stress) that is induced into the part will make it stronger. Other processes can meet the improved wear resistance of the added hardness but fail to strengthen the part at all, or not as much as induction hardening.

Single piece flow – Because induction hardening is not a batch process (typically one part is hardened at a time), induction machines can be placed in a manufacturing cell, allowing the process flow to be uninterrupted.

Equipment and Tooling

Induction Hardening Machine – Systems will vary significantly in size and complexity depending on the components they are hardening. The primary components of the machine consist of a power supply, heat station (transformer), workstation, and HMI. The fluids system is composed of quenchant to cool the part being hardened and distilled water to cool the internal components of the machine. Heat time, power supply output, part rotation, and quenchant parameters should be controlled, monitored, and logged for each part.

Power Supplies – Power supplies are the most important component of the induction hardener. For the purpose of this article, we will discuss the two most important outputs of the power supply, frequency and power.

Frequency is important because it will help determine the depth of heating. Lower frequencies heat deeper into the part, and higher frequencies heat closer to the surface. To remember this, I like to use the analogy of whales using very low frequency calls to communicate over miles and miles of ocean, whereas the high-pitched squeak of a mouse can only be heard several feet away. For induction hardening, frequencies are split into two groups: medium frequency (MF) and radio frequency (RF). The MF range is typically from 3-50kHz, and RF is from 100-400kHz.

Power is important because it will determine how large of a part you can harden, and how long the heat time will need to be. The more power that a machine can output, the larger the part it can harden and the faster it can harden to a specified case depth. Typical power supply outputs for induction hardening range from 25kW to 1MW.

Coils – The induction coil is a copper conductor that is shaped in order to harden the specified area of the part. The current that flows through the coil is what produces the magnetic field, which in turn heats the part. Coils are typically part specific, since they need to be precisely constructed to heat a particular portion of the part.

Modern induction coils are water cooled and can be made of tubing or machined copper pieces that are brazed together to make a particular shape to fit the part. They are frequently equipped with sections of a material called flux intensifier, which helps to drive the magnetic field in a certain direction in order to intensify heating in that area and make the coil more efficient.

It is also common to have the quenching designed into the coil (machine integral quench, or MIQ) so that quenchant can be applied immediately after heating without the need to move the part to an auxiliary quench mechanism.

Process Basics

Single Shot – Single shot hardening is the most common method of induction hardening where the part and coil remain in the same spot during the heating process. Typically, the part is brought into proximity of the coil, the heating and quenching processes are applied to the part, and then the part is removed from the coil.

Scanning – Scanning involves heating and quenching a small portion of the part while moving either the coil or the part until the desired area is hardened. Quench is directionally applied to the part so that as a new portion of the part is heated, the previously heated section is being quenched appropriately. Scanning is frequently used to harden shafts because heating the entire shaft at once would require too much power.

Dual Frequency – Dual frequency hardening combines the benefits of the deeper heating of the lower MFs with the surface heating capabilities of higher RFs. By utilizing two different frequencies, it is possible to contour the hardening pattern more effectively on gear-like components, which further improves the strength of the part. The frequencies can either be applied consecutively (low frequency preheat followed by a high frequency final heat) or simultaneously.

Induction Tempering – Induction can also be used to complete the temper process in a few seconds rather than furnace tempering which could take hours. Induction tempering takes place after the hardening process and involves heating the part to a much lower temperature than is required during hardening. The targeted temperature for induction temper is higher than that of furnace tempering due to the decreased temper time. This softens the hardened area slightly in order to increase the toughness of the part and improve crack susceptibility.

Quenching – The quench process is just as important as the heating process with induction hardening. Almost all modern systems use a water/polymer quenchant mixture in the range of 5-20% polymer instead of using oils. The quench media is typically sprayed on to the part rather than submerging it into a bath. Quench concentration, temperature, flow, and pressure must all be monitored closely for a robust process. These parameters all function to guarantee that the part is quenched properly and consistently to ensure the correct hardness is achieved and crack susceptibility is minimized. Quench media must also be filtered to remove any process waste that could potentially clog the quench spray holes.

Inspection – Like most other forms of heat treatment, the two most common specifications with induction hardening are case depth and hardness. Most specifications will require surface hardness measurements along with effective case depths to determine the depth of hardening.

Materials – The most common materials to be induction hardened are medium to high carbon and alloy steels, cast irons, and powder metal. Induction is also becoming a popular heat treat method on certain stainless steels in different industries.

What to Look Out For

Cracking – The rapid expansion of the part during heating followed by shrinkage from the accelerated cooldown during quenching increases crack susceptibility of induction hardened parts. Not all parts have a high risk of cracking, but part characteristics such as internal holes, sharp edges, and certain higher carbon materials will require more consideration. If cracking is an issue, the first two areas to investigate are overheating and quench severity. Reducing the quench severity (increasing quench temperature and concentration, reducing flow and pressure) is typically the most effective means of reducing cracking within an induction hardened part.

Distortion – Another side effect of the rapid expansion and contraction is part distortion. It is impossible to not distort the part with induction hardening due to the phase changes in the metal. However, with a robust and carefully monitored process, it is possible to minimize and accurately predict process distortion. Faster heating times and technical expertise in fixturing methods are two common methods to reduce distortion.

Conclusion

Although this information just begins to scratch the surface of the terminology and fundamentals of the process, hopefully it provides a starting point to those with limited experience. Like many other forms of heat treatment, it can take years to develop the knowledge and skills to gain expertise in induction hardening. I have been involved in induction for almost fifteen years, and I find there is always a new application that gives me the opportunity to learn even more.

About the Author: Kyle Hummel is a licensed Professional Engineer who has worked for Contour Hardening for 15 years as a metallurgical engineer and currently manages operations of Contour’s Indianapolis location.

For more information, contact Kyle at khummel@contourhardening.com or 317.876.1530 ext. 333